EP1859922B1 - Réparation de structures composites en sandwich dotées de surfaces à liaison inégale et structure composite en sandwich - Google Patents

Réparation de structures composites en sandwich dotées de surfaces à liaison inégale et structure composite en sandwich Download PDF

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Publication number
EP1859922B1
EP1859922B1 EP07252023A EP07252023A EP1859922B1 EP 1859922 B1 EP1859922 B1 EP 1859922B1 EP 07252023 A EP07252023 A EP 07252023A EP 07252023 A EP07252023 A EP 07252023A EP 1859922 B1 EP1859922 B1 EP 1859922B1
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EP
European Patent Office
Prior art keywords
honeycomb
skin
repair
recited
section
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EP07252023A
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German (de)
English (en)
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EP1859922A1 (fr
Inventor
William Bogue
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RTX Corp
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United Technologies Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C73/00—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D
    • B29C73/04—Repairing of articles made from plastics or substances in a plastic state, e.g. of articles shaped or produced by using techniques covered by this subclass or subclass B29D using preformed elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/60—Multitubular or multicompartmented articles, e.g. honeycomb
    • B29L2031/608—Honeycomb structures
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24149—Honeycomb-like
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24149—Honeycomb-like
    • Y10T428/24165—Hexagonally shaped cavities
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y10T428/24446—Wrinkled, creased, crinkled or creped
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31—Surface property or characteristic of web, sheet or block

Definitions

  • This invention relates to composite materials and, more particularly, to repairing composite sandwich structures.
  • Composite structures are commonly known and used in, for example, gas turbine engines for aerodynamic fairings.
  • One type of composite is a sandwich structure having a face skin and a back skin that are bonded to a honeycomb core.
  • the face skin and back skin may be laminated structures with a resin matrix, such as epoxy, with one or more plies of reinforcement fibers.
  • Laminated skins are fabricated in a process that involves compacting the resin filled plies of reinforcing fiber together while curing the resin.
  • the texture of the tooling materials used on each molded face of the laminate during compaction and cure will be observed on the resulting laminate surface. If one or more of the molded faces is restrained by a non-rigid material, textures may telegraph thru the thickness of the laminate.
  • compaction against the ends of the honeycomb locally press into the skins and form a dimpled imprint surface.
  • honeycomb that has become damaged from an impact, elevated temperatures, abrasion, erosion, or other phenomenon rather than replace the entire composite structure.
  • the honeycomb is machined to have a flat surface on both sides. The flat surfaces do not conform well with uneven surfaces without crushing the honeycomb. It is unfeasible to have the ends of the replacement honeycomb align perfectly with the dimpled imprints left by the removed honeycomb section.
  • the damaged honeycomb is removed and an adhesive is applied to the laminate dimpled imprint surface to bond the skin and a replacement honeycomb together.
  • an additional thickness of adhesive is used to "absorb" the unevenness of the dimpled imprints.
  • An example method disclosed herein of restoring a section of a component having a honeycomb bonded to a skin includes the steps of separating the face sheet and the original honeycomb from a skin, wherein the skin includes an uneven surface. At least a portion of the uneven bond surface is thinned to form a more even bonding surface on the laminate. A conformable is applied over the bond surface. A replacement honeycomb is then pressed into the conformable layer. The conformable layer and the adhesives are cured to restore original component structure.
  • An example composite component disclosed herein includes a sandwich structure with a honeycomb, a laminate that is bonded to each side of the honeycomb, and a repair section.
  • the repair section includes an uneven laminate from the original component, a repair piece of honeycomb, a replacement laminate, a conformable layer, and adhesives to bond the repair section to itself and the adjacent areas.
  • Figure 1 illustrates selected portions of an example composite structure 20, such as an acoustic composite used in a fan- bypass area or nacelle of a gas turbine engine for noise attenuation.
  • the composite structure 20 includes a face skin 22, which may include perforations 23 that extend through the thickness of the face skin.
  • the face skin 22 and a back skin 24 are bonded to a honeycomb core 26 to provide a composite sandwich structure.
  • each of the face skin 22 and the back skin 24 include composite layers 28, such as layers made of a resin matrix with continuous woven fiber reinforcement that are concurrently bonded to and compacted against the ends of honeycomb core 26.
  • the honeycomb core 26 has become damaged by, for example, an impact, elevated temperatures, abrasion, erosion, or other phenomenon.
  • the composite structure 20 is repaired by removing the damaged honeycomb core 26 and replacing it with a replacement honeycomb core 26' ( Figure 4 ).
  • the replacement honeycomb core 26' is bonded to the back skin 24 to provide a structurally durable repair that is dimensionally similar to the original dimensions of the composite structure 20.
  • the composite structure 20 is repaired in several steps.
  • the damaged face skin 22 and honeycomb core 26 are locally removed from the back skin 24 at step 42.
  • the disclosed example describes removal from and bonding to the back skin 24, it is to be understood that the principles of the repair are also applicable to the face skin 22.
  • Removal of the damaged honeycomb core 26 reveals an uneven surface 45 on the back skin 24 caused by the original manufacture of the back skin 24.
  • the uneven surface 45 is partially leveled to produce a more even bonding surface 47.
  • the replacement honeycomb core 26' is bonded to the bonding surface 47 of the back skin 24.
  • the disclosed method provides the benefit of reducing surface variation on the back skin 24 to enable formation of a stronger bond between the replacement honeycomb core 26' and the back skin 24.
  • Figure 3 shows the back skin 24 after the removal step 42.
  • the back skin 24 includes the uneven surface 45.
  • the uneven surface 45 is a product of the fabrication process of the original composite structure 20.
  • the composite stricture 20 was compacted and cured in a known manner, which resulted in the uneven surface 45.
  • ends 50 of the honeycomb core 26 press into the back skin 24 and form the dimpled imprint illustrated in Figure 3 .
  • the dimpled imprint includes compacted (compressed/consolidated) sections 52 where the ends 50 of the honeycomb core 26 pressed into the back skin 24, and relatively uncompressed sections 54 that were between the ends 50 and therefore not compacted as much.
  • a portion 56 of the uneven surface 45 is removed to produce the bonding surface 47.
  • the portion 56 can be removed in a variety of different ways. In one example, the portion 56 is mechanically removed using a grinding, sanding, or other known mechanical process.
  • the back skin 24 includes three fiberglass layers 28 with a cured epoxy resin matrix.
  • the high spots of the top composite layer 28. i.e., the top layer in Figure 3
  • the middle composite layer 28 is at least partially exposed on the bonding surface 47.
  • the removal of the portion 56 from the back skin 24 provides the benefit of reducing surface variation on the uneven surface 45. This provides a flatter surface to bond to, and thereby allows a stronger bond to be formed between the bonding surface 47 and the replacement honeycomb core 26'.
  • more than one composite layer 28 or less than one composite layer 28 may be removed, depending on the desired reduction in surface variation.
  • a conformable repair material 66 is placed onto the bonding surface 47.
  • a layer of adhesive 68a is used between the repair material 66 and the bonding surface 47 to strengthen the bond between the back skin 24 and the repair material 66.
  • the repair material 66 is a composite layer 28' that is similar to or identical to the composite layers 28 used in the back skin 24, except that it is not compacted and the resin is not cured.
  • the conformable repair material 66 is made of an uncured epoxy resin matrix with continuous woven fiberglass reinforcement.
  • Using the composite layer 28' provides the benefits of absorbing tolerance variation between the original honeycomb and repair material 66, providing additional smoothing for intimate contact with the honeycomb ends 50, restoring structural strength lost by removal of the uncompressed portions 56, and thicker regions of adhesive thickness are interrupted by the fiber reducing the strength debit due to adhesive thickness.
  • Another layer of adhesive 68b is used on top of the conformable repair material 66 to promote bonding between the conformable repair material 66 and the replacement honeycomb core 26'.
  • compaction of the face skin 22, the replacement honeycomb core 26', and the back skin 24 occurs under pressure at an elevated temperature to cure the resin of the conformable repair material 66 and adhesive layers 68a and 68b.
  • the ends 50' of the replacement honeycomb core 26' compress portions of the repair material 66 immediately below the ends 50', while the repair material 66 between the ends 50' is relatively uncompressed, mimicking the original sandwich structure.
  • Figure 5 illustrates the composite structure 20 after the repair process.
  • the repair material 66 is fully cured and compacted to a dimension d 1 that is about equal to a dimension d 2 ( Figure 1 ) and a dimension c 1 that is about equal to a dimension c 2 ( Figure 1 ) of the composite sandwich structure 20 before the repair (e.g., before damage to the honeycomb core 26).
  • the disclosed example method of repair provides a structurally durable repair section that is dimensionally and functionally equal with surrounding areas of the composite sandwich structure 20 that have not been repaired.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)

Claims (14)

  1. Procédé de restauration d'une section d'un composant (20) comprenant un nid d'abeilles (26) lié à une pellicule (24), comprenant les étapes suivantes:
    (a) séparer un premier nid d'abeilles (26) d'une pellicule (24) qui présente une surface inégale (45);
    (b) enlever au moins une partie de la surface inégale (45) afin de former une surface de liaison (47) sur la pellicule (24); et
    (c) déposer une première couche adhésive (68a) sur la surface de liaison (47), déposer un matériau de réparation (66) comprenant des fibres de renforcement continues à l'intérieur d'une matrice de résine sur la première couche adhésive (68a), déposer une deuxième couche adhésive (68b) sur le matériau de réparation (66), et lier un deuxième nid d'abeilles différent (26') à la surface de liaison (47).
  2. Procédé selon la revendication 1, dans lequel la surface inégale (45) comprend des sections comprimées (52) et des sections non comprimées (54), et l'étape (b) comprend l'enlèvement d'au moins une partie des sections non comprimées (54).
  3. Procédé selon la revendication 1 ou 2, comprenant le nettoyage de la surface de liaison (47) après l'étape (b).
  4. Procédé selon l'une quelconque des revendications précédentes, dans lequel l'étape (c) comprend en outre le dépôt d'un matériau de réparation adaptable (66) sur la surface de liaison (47) afin de lier le deuxième nid d'abeilles (26') et la surface de liaison (47) l'un à l'autre.
  5. Procédé selon la revendication 4, dans lequel l'étape (c) comprend en outre le pressage du deuxième nid d'abeilles (26') dans le matériau de préparation adaptable (66).
  6. Procédé selon la revendication 5, dans lequel l'étape (c) comprend en outre le durcissement du matériau de réparation adaptable (66) afin de lier le deuxième nid d'abeilles (26') et la surface de liaison (47) l'un à l'autre.
  7. Procédé selon l'une quelconque des revendications précédentes, dans lequel la pellicule (24) comprend des couches (28) de matériau composite de fibres continues, et l'étape (b) comprend l'enlèvement complet d'une partie d'une couche supérieure des couches (28) de telle sorte qu'une couche située en dessous de la couche supérieure soit exposée.
  8. Composant composite (20), comprenant:
    une pellicule (24) présentant une surface inégale (45) qui est liée à un premier nid d'abeilles (26);
    une surface de liaison nivelée (47) sur la pellicule (24);
    un deuxième nid d'abeilles différent (26'); et
    une section de réparation constituée d'un matériau composite qui présente une matière de matrice et des fibres de renforcement, dans lequel la section de réparation lie le deuxième nid d'abeilles (26') à la surface de liaison (47) sur la pellicule (24).
  9. Composant selon la revendication 8, dans lequel la section de réparation comprend un matériau de réparation (66) qui comprend les fibres de renforcement continues à l'intérieur d'une matrice de résine.
  10. Composant selon la revendication 9, dans lequel le matériau de réparation (66) comprend une section comprimée et une section non comprimée.
  11. Composant selon la revendication 9 ou 10, dans lequel la section de réparation comprend une première couche adhésive (68a) entre la pellicule (24) et le matériau de réparation (66).
  12. Composant selon la revendication 11, dans lequel la section de réparation comprend une deuxième couche adhésive (68b) entre le deuxième nid d'abeilles (26') et le matériau de réparation (66).
  13. Composant selon l'une quelconque des revendications 10 à 12, dans lequel la section comprimée correspond à une extrémité du deuxième nid d'abeilles (26'), et la section non comprimée est espacée de l'extrémité du deuxième nid d'abeilles (26').
  14. Composant composite (20) selon l'une quelconque des revendications 8 à 13, dans lequel les premier et deuxième nids d'abeilles (26, 26') sont liés entre la pellicule (24) et une pellicule perforée (22).
EP07252023A 2006-05-26 2007-05-17 Réparation de structures composites en sandwich dotées de surfaces à liaison inégale et structure composite en sandwich Active EP1859922B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US11/441,866 US7572347B2 (en) 2006-05-26 2006-05-26 Repair of composite sandwich structures with uneven bond surfaces

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EP1859922A1 EP1859922A1 (fr) 2007-11-28
EP1859922B1 true EP1859922B1 (fr) 2012-10-03

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EP (1) EP1859922B1 (fr)
JP (1) JP2007313895A (fr)

Cited By (1)

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EP2944455A1 (fr) 2014-05-14 2015-11-18 AIRBUS HELICOPTERS DEUTSCHLAND GmbH Procédé de réparation d'un composant en sandwich ayant un noyau en nid d'abeilles qui est disposée entre une première et une seconde plaque de recouvrement

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Publication number Priority date Publication date Assignee Title
EP2944455A1 (fr) 2014-05-14 2015-11-18 AIRBUS HELICOPTERS DEUTSCHLAND GmbH Procédé de réparation d'un composant en sandwich ayant un noyau en nid d'abeilles qui est disposée entre une première et une seconde plaque de recouvrement

Also Published As

Publication number Publication date
US20070275211A1 (en) 2007-11-29
US20090263622A1 (en) 2009-10-22
US7883760B2 (en) 2011-02-08
JP2007313895A (ja) 2007-12-06
EP1859922A1 (fr) 2007-11-28
US7572347B2 (en) 2009-08-11

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